Wiring harness assembly for an intake manifold

Abstract

A wiring assembly for a plastic intake manifold mounted to an internal combustion engine of a motor vehicle includes a flexible circuit assembly disposed within foam covering the intake manifold. The flexible circuit assembly provides for electrical communication between a controller and a plurality of electrical devices. In one embodiment the electrical devices are integral to the flexible circuit assembly to create a flexible circuit/electrical device assembly forming a single replaceable unit. In another embodiment, multiple flexible circuits are sandwiched between layers of foam, with each flexible circuit separated from the others by layers of foam. Each of the multiple flexible circuits attaches to different types electrical devices or sensors. The invention also provides for a decorative skin disposed over the layers of foam that may include a printed design to eliminate the need for an additional decorative engine cover.

What is claimed is:  
     
       1. A wiring harness assembly for an intake manifold mounted to an internal combustion engine comprising; 
       a plurality of electrical devices;  
       at least two layers of foam disposed on said intake manifold; and  
       a flexible circuit assembly sandwiched between said layers of foam and connected to said plurality of electrical devices.  
     
     
       2. The assembly of  claim 1 , wherein said flexible circuit assembly includes at least one input connector and a plurality of output connectors for attachment to said plurality of electrical devices. 
     
     
       3. The assembly of  claim 1 , wherein said flexible circuit is formed onto one of said layers of foam. 
     
     
       4. The assembly of  claim 1 , further including a plurality of flexible circuits sandwiched between said layers of foam, each of said flexible circuits separated from each of the other flexible circuits by said layers of foam. 
     
     
       5. The assembly of  claim 1 , further including another flexible circuit assembly and a third layer of foam, said third layer of foam separating said flexible circuit assemblies sandwiched between said layers of foam. 
     
     
       6. The assembly of  claim 1 , wherein said flexible circuit assembly and said electrical devices are one integral assembly such that the entire flexible circuit assembly and said electrical devices are replaceable as one unit. 
     
     
       7. The assembly of  claim 1 , wherein said foam is attached to said intake manifold with a plurality of mechanical fasteners. 
     
     
       8. The assembly of  claim 1 , wherein said intake manifold is fabricated from a plastic material. 
     
     
       9. The assembly of  claim 1 , wherein one of said layers of foam includes a decorative skin. 
     
     
       10. The assembly of  claim 9 , wherein said decorative skin further includes a printed design. 
     
     
       11. A wiring harness assembly for an intake manifold mounted to an internal combustion engine comprising; 
       at least two layers of foam disposed on said intake manifold;  
       a flexible circuit assembly including a plurality of integral electrical devices;  
       said flexible circuit assembly sandwiched between said layers of foam and said flexible circuit assembly and said electrical devices are replaceable as one unit.  
     
     
       12. The assembly of  claim 11 , wherein said flexible circuit assembly includes an output connector for connection to a controller of the motor vehicle. 
     
     
       13. The assembly of  claim 11 , wherein said plurality of electrical devices includes at least one fuel injector. 
     
     
       14. The assembly of  claim 11 , wherein said plurality of electrical devices includes sensors disposed within said intake manifold. 
     
     
       15. The assembly of  claim 11 , wherein said intake manifold is fabricated from plastic.